On3425302537

Gautam B.Ghegadmal, Late.Prof. Ashok S. Patole, Prof. Vaishali S. Kumbhar, Prof. Vinayak

H. Khatawate / International Journal of Engineering Research and Applications (IJERA)

ISSN: 2248-9622 www.ijera.com Vol. 3, Issue 4, Jul-Aug 2013, pp.2530-2537

2530 | P a g e

Productivity Improvement in Automated Material Handling

System of Liquor Manufacturing Plant

Gautam B.Ghegadmal1, Late. Prof. Ashok S. Patole

2, Prof. Vaishali S.

Kumbhar3, Prof. Vinayak H. Khatawate

4

1. (M.E.Scholar, Department of Mechanical Engineering, PIIT, New Panvel, Navi Mumbai, India

2. (Late. Assistant Professor, Department of Mechanical Engineering, PIIT, New Panvel, Navi Mumbai, India

3. (Assistant Professor, Department of Mechanical Engineering, PIIT, New Panvel, Navi Mumbai, India

4. (Assistant Professor, Department of Mechanical Engineering, PIIT, New Panvel, Navi Mumbai, India

ABSTRACT Material handling systems are commonly

used in almost all the industries in all over the

world. It is an art and science involving moving,

packaging and storing of substances in any form.

In the field of engineering and technology, the

term material handling is used with reference to

industrial activity. This report contains an

automated material handling system used for

manufacturing alcohol from agricultural products

(grain, sugar and flour etc.). It consists of PLC

(Programmable Logic Controller), SCADA

(Supervisory Control and Data Acquisition

System) or DCS (Distributed Control System) to

visualize and control the system. Modifications are

carried out in this automated material handling

system used in liquor manufacturing plant, one at

conveyor system and other at crushing section.

These modifications have resulted in a great

productivity improvement.

Keywords - Automation, Liquor manufacturing

plant, Material handling system, Productivity

improvement.

I. INTRODUCTION Automation is concerned with the

application of electro-mechanical devices, electronics

and computer-based systems to operate and control

production and service activities. It suggests the

linking of multiple mechanical operations to create a

system that can be controlled by programmed

instructions [1, 2]. Material handling operations

should be mechanized and/or automated where

feasible to improve operational efficiency, increase

responsiveness, and improve consistency and unsafe

manual labor [3, 4]. Still there is scope for

improvement by preventing frequent breakdowns,

occurring due to some design level parameters [5], as

shown in this paper.

II. PROBLEM STATEMENT 2.1. Case study 1: Pipe leakage problem of

conveying pipe (Material: M.S.) at the bend

section (Plant 1)

The problem was severe as pneumatic

conveying system was not working properly and was

facing the problem of leakage of conveying pipe at

the bend section. The target to be achieved was

productivity improvement by removal of the above

problem [6, 7].

2.2. Case study 2: Chocking of bags of bag filter

(Plant 1)

The problem was severe as bag filter

/product separator was not working properly and was

facing the problem of chocking of bags of bag filter.

The target to be achieved was productivity

improvement by removal of the above problem [6, 7].

2.3. Case study 3: Vibration of hammer mill

(Plant 2)

During commissioning of plant at No load

trial (i.e. empty equipment trail), the hammer mill

was facing the problem of vibration. The target to be

achieved was reducing the vibration of hammer mill

[6, 7].

III. METHODOLOGY AND COST-

BENEFIT ANALYSIS 3.1. Methodology and Cost-Benefit Analysis of

Case study 1: Pipe leakage

3.1.1. Methodology

It was understood from a consultant that

during commissioning of plant 1, at full load trail,

pneumatic conveying pipe (Material: M.S.) was

causing wear and tear at the bend section. Due to this,

M.S. pipe was getting hole at the bend sections and

material i.e. grain, was coming out from that holes

with high pressure. The problem was examined in the

shop floor area in detail. To find out the various

causes of pipe leakage, brainstorming session was

carried out with the guide and experienced people in

the company. At the same time data was collected

regarding break down and studied the types of break

downs. Following points were note down and causes

of leakage of pipe were found out. These things are

arranged in the form of “Cause and effect diagram”,

as follows [8]:




2531 | P a g e

Fig.1.Cause and effect diagram of leakage of bend

pipe

It was concluded that, at the bend section,

the bend pipe material should be anti-corrosion, anti-

wearing, good hardness, high chemical stability, of

which the leakage of bend pipe is avoided. In-depth

literature review was carried out on different anti-

corrosion, anti-wearing materials, “Cast Basalt” was

selected for the bend pipe because of its following

excellent features, benefits and applications [9].

3.1.2. Features i. Cast basalt is having outstanding wear

resistance.

ii. 8 on the Mohs hardness scale, diamond has a

value of 10.

Iii. Service temperatures up to 7000

F or down to -

400 F.

iv. Maintains a smooth even surface for favorable

flow conditions.

v. Available in straight pipes, bends and fittings.

vi. Multiple end options available, including flanges

and weld ends.

3.1.3. Benefits i. Long life in highly abrasive and corrosive

applications.

ii. Excellent service life at cost effective pricing.

iii. Improved performance compared to alternate

linings.

3.1.4. Applications

Cast basalt applications include hydraulic

piping systems for materials such as bottom ash, fly

ash, pulverized coal, lime and many other abrasive

transport applications. Cast basalt is ideal for

improving system performance and life.

TABLE 1

Breakdown Data of Leakage of Bend Pipe

Fig.2.Inside coating of cast basalt bend pipe:Before

Sr.

No.

Break

down

(after

hrs.)

Time

reqd.

(hrs.

/day)

Procedure carried out

1. 5 6

Bend pipe was welded at the

leakage section and set up the

system.

2. 2 5



system.

3. 4 5



system.

4. 5 1 Bend pipe of original shape

was changed.

5. 1 8

Bend pipe of new shape was

Installed in the pneumatic

conveying system.

6. 2 5

Bend pipe of new shape was

welded and installed in the

pneumatic conveying system

7. 1 5

Again Bend pipe of new

shape was welded and

installed in the pneumatic

conveying system.

8. 3 20 days

M.S bend pipe having inside

Coating of cast basalt was

ordered from Pune and was

installed in the pneumatic

conveying system.




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Fig.3.Before implementing M.S. bend pipe having

inside cast basalt coating

Fig.4.After implementing M.S. bend pipe having

inside cast cast basalt coating

For movement of grains, as per design

considerations, the radius of bend pipe was made 5D

times where D is the diameter of pneumatic

conveying pipe. Then grains are moving through the

bend section. In this way the problem is solved and

the system is working successfully.

3.1.5. Cost-Benefit Analysis

Calculation of monetary loss during breakdown

period (including all the expenditures):

Breakdown period is of six hrs. Capacity of

alcohol production is 100 KLPD. During breakdown

period of six hrs. The total expenditure (i.e. Total

loss) was Rs. 13, 38,200.00. But due to complete

solution on leakage problem, the company is now

benefitted by Rs.13, 38,200.00.

TABLE 2

Cost Analysis of Leakage of Bend Pipe

3.2. Methodology and Cost-Benefit Analysis for

case study 2: Chocking of bags

3.2.1. Methodology

It was understood from Consultant that

during commissioning of plant 1 at full load trail,

when the material moves through pneumatic

conveying pipe (Material: M.S.) and enter into

Product separator (Bag filter) for separation of air

and grain, there was a problem of chocking of bags of

bag filter after every two to three hrs. and the system

was tripping.

To find out the various causes of chocking

of bags of bag filter, brainstorming sessions were

carried out with the guide and experienced people in

the company.

It was concluded that, the grain and air

before entering into bag filter should be separated

out. Finally, it was decided to install “Cyclone

Separator” in between bag filter and blower on the

pneumatic conveying pipe.

Sr.

No

.

Descri-

ption

Charg

es/

Shift

Cost

in Rs.

Qty.

/per-

sons

Total

Rs.

1. Labor

Charges 200 ----- 06 1200/-

2. Maintenance Charges:

a) Elect.

Engineer 1000 ----- 01 1000/-

b) Elect.

Assistant 400 ------ 02 800/-

c) Mech.

Engineer 1000 ------ 01 1000/-

d) Mech.

Assistant 400 ------ 03 1200/-

3. Removal

of broken

piece

cost

------- 1500 02 3000 /-

4. Alcohol

Produc-

tion loss

cost

------ 50

Per liter

25

KL

PD

12,50,000/-

5. Cast

basalt

bend

pipe cost

------ 40,000 02 80,000 /-

Total 13,38,200/-




2533 | P a g e

Fig.5. Cause and effect diagram of chocking of bags

3.2.2. Operation of Cyclone Separator

A cyclone is centrifugal separator, where the

particles are swung by the centrifugal force to the

outside, as a result of their mass. The entering air is

automatically forced a rapidly spinning double vortex

movement, so-called “double vortex”. This double

vortex movement exists from the outside stream that

flows spirally down and the inside stream, which

flows spirally up. Both the airs flow from one to the

other on the border area. The particles that are

present in the air flow swung to the outside wall and

leave the separator through a reception space situated

to the base.

Fig.6.Before implementing cyclone separator in

between bag filter and blower

It‟s salient features are, simple construction,

no moving components, little maintenance, constant

pressure drop and low investment and functioning

costs. It‟s applications are in cement, chemicals,

petrochemicals, pharmaceuticals, distillery or

brewery, food industry, paint and pigment handling,

mineral processing plants.

TABLE 3

Breakdown Data of Chocking of Bags of Bag Filter

Sr.

No.

Break

down

After

Hrs.

Time

Reqd.

(Hrs.) Procedure carried out

1. 2 5

Chocked bags were taken out

from bag filter, cleaned and

again put into bag filter.

2. 2 6




3. 3 5




4. 2 4




5. 2 25

days

New cyclone separator was

fabricated at consultant and

installed at plant 1.

Fig.7A. After implementing cyclone separator in

between bag filter and blower (With bend pipe and

cyclone separator)

Fig.7B. After implementing cyclone separator in

between bag filter and blower (With cyclone

separator, duct and bag filter)




2534 | P a g e


Calculation of monetary loss during breakdown

period (including all the expenditures):

Breakdown period is four hrs. Capacity of

alcohol production ═ 100 KLPD

TABLE 4

Cost Analysis of Chocking of Bags

Sr

N

o. Descrip-

tion

Cha

rges

per

Shift

Cost

in Rs.

Qty./

per-

sons Total

Rs.

1. Labor

Charges 200 ----- 04 800 /-


a) Elect.

Engineer 1000 ----- 01 1000 /-

b) Elect.

Assistant 400 ------ 02 800 /-

c) Mech.

Engineer 1000 ------ 01 1000 /-

d) Mech.

Assistant 400 ------ 03 1200 /-

3. Alcohol

Product-

ion loss

cost

---- 50

Per liter

16.6

KL

PD

8,33,333/-

4. Cyclone

separator

cost ---- 1,70,000 01 1,70,000/-

5. Duct and

stand cost 40,000 01 40,000/-

Total 10,48,133/

-

During breakdown period of four hrs, the

total expenditure (i.e. Total loss) was Rs.10,

48,133.00. But due to complete solution on chocking

of bags problem, the company is now benefitted by

Rs.10, 48,133.00.

3.3. Methodology and Cost-Benefit Analysis for

Case Study 3: Vibration of hammer mill

3.3.1. Methodology

It was understood from consultant that plant

3 is ready for commissioning. The vibration of

hammer mill was reduced step by step by doing

following improvements [10]:

Step I: Improvements on first day i. Checking of all the loose parts and tightening the

nut bolts.

ii. Initially, some of the belts of the motor pulley

were in overlapped condition, so they were

arranged in proper manner.

iii. Align motor pulley and hammer mill pulley.

Again trial was taken but due to above

improvements, 5 to 10% vibrations are reduced.

After a close examination over it, the author

suggested to reduce the vibration by making the

base strong.

Less Soil

Careless Skilled Absentees of

civil Poor anti-vibrating

workers maint. pads

Improper Saving

arrangement Poor

of belts . quality Centre

position

Fig.8. Cause and effect diagram of vibration of

hammer mill

Fig.9. Hammer mill after vibration and breakage of

concrete base

Step II: Improvements on second day i. Measurements were taken between each two leg

supports of hammer mill [11].

ii. Four „I‟ beams were cut into suitable lengths and

connected in between the leg supports by

welding.

Fig.10. Hammer mill after connecting „I‟ beams

between the Supports

Again trial was taken but due to above

improvements, 30 to 40 % vibrations are reduced.

VIBRAT-

ION OF

HAMMER

MILL

METHOD MATERIALS MEASURMENTS

TS

MACHINE MOTHER NATURE MANPOWER




2535 | P a g e

For controlling more vibration, the author was

suggested to put anti-vibrating pads wherever

required and increase the number of eye foundation

bolts.

Step III: Improvements on fourth day

i. With the help of chain block, the jaws of mill

were opened and the anti-vibrating pads were

kept between the two jaws

ii. Also anti-vibrating pads were kept as per the

requirements

iii. Four iron plates were cut into suitable sizes and

drilled near the corners for the passage of eye

foundation bolts.

iv. The plates were kept below each support and

welded.

v. Four eye foundation bolts were fixed to each

plate in the concrete base.

After eight days, when trial was taken, it

was observed that 85 to 90 % vibration is reduced.

Remaining 10 to 15% vibration is allowed.


Calculation of monetary loss during controlling of

vibration of hammer mill (including all

expenditures):

Considering six days period:

TABLE 5

Cost Analysis of Vibration of Hammer Mill

So during trial period of six days, the total

expenditure (i.e. Total loss) was Rs.40, 850/-. But

due to 85 to 90% solution on vibration problem, the

company is now benefitted by Rs. 40,850/-

IV. PROJECT MILESTONES Total work done during the project may be

summarized in the form of DMAIC methodology of

Six Sigma as follows [8]:

TABLE 6

Project Milestones

Frequently occurring breakdowns like

leakage of bend pipe, chocking of bags and vibration

of hammer mill may be quantified for drawing Pareto

chart [8].

TABLE 7

Analysis Sheet for Pareto Chart

S

r.

N

o.

Descrip-

tion

Cha

rges

per

day

Cost

per

Kg.

Qty

in

Kg

Pers-

ons Total

Rs.

1. Labor

Charges 150 ----- ---- 05 4500/-


a) Elect.

Engineer 1000 ----- ---- 01 6000/-

b)Elect.

Assistant 350 ------ ---- 02 4200/-

c) Mech.

Engineer 1000 ------ ---- 01 6000/-

d) Mech.

Assistant 350 ------ ---- 03 6300/-

e) Civil

Engineer 1000 ------ ---- 01 6000/-

f) Civil

Assistant 350 ------ ---- 01 2100/-

3. 12”Eye

foundati-

on bolts

on bolt

------ 45 10 ------ 450/-

4. Cement ------ ---- ---- ---- 1000/-

5. „I‟ beam ------ 55 60 3300/-

6. Anti-vibr

ating pads ---- --- ---- ----- 1000/-

Total 40,850/-

S

r.

N

o.

Plant

Phases

Plant 1 A

Plant 1 B

Plant 2

Problem

Leakage of

bend pipe of

conveying

system

Chocking

of bags of

bag filter.

Vibration

of hammer

mill

1. Define One week One week One day

2. Measure One week One week Two days

3. Analysis Two weeks Two week Three days

4. Improve-

ment Two weeks One week Six days

5. Control Two weeks One week Two days

Total

duration

Eight

weeks

Six

weeks

Two

weeks

S

r. Types of

Breakdown

Freq. of

Breakd

own

% of Total

Breakdown

Cumul-

ative

%

1. Leakage of

bend pipe 8 50% 50 %

2. Chocking of

bags 5 31.25% 81.25%

3. Vibration of

hammer mill 3 18.75% 100%

Total 16 100% 100%




2536 | P a g e

Fig.11.Pareto chart

V. FINAL COST-BENEFIT ANALYSIS We can summarize profit obtained by two

plants as follows:

TABLE 8

Final Cost- Benefit Analysis

VI. CONCLUSION After completing above said improvements

in automated material handling system of liquor

manufacturing plants, the productivity increased to a

great extent in monitory terms. Workers were

extremely satisfied due to removal of regular

problems viz. leakage of bend pipe, chocking of bags

of bag filter and vibration of hammer mill. There

were intangible benefits like smooth co-ordination

between management and workers, overall employee

satisfaction, external customer requirement

fulfillment, etc. Due to this project, the employee-

employer relationship has also strengthened to a large

extent.

VII. ACKNOWLEDGEMENT Authors are thankful to all the authors and

contributors of the papers which are referred while

preparing this paper.

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systems and computer integrated

manufacturing (Tata McGraw-Hill

Publication Ltd., Third Edition, New Delhi),

781-786.

[2] Eckert, K., Frank, T., Hadlich, T.,Fay, A.,

Vogel-Heuser B., Diedrich, Typical

Automation Functions and Their

Distribution in Automation Systems,

Emerging Technology & Factory

Automation (ETFA) 2011, IEEE 16th

Conference on

10.1109/ETFA.2011.6059123, 1-8.

[3] Sebastian Faltinski, Oliver Niggemann,

Natalia Moriz, and Andre Mankowski,

Automation ML: From Data Exchange to

System Planning and Simulation,

International Conference on Industrial

Technology (ICIT), 2012 IEEE International

Conference on 10. 1109/ICIT.2012.62099,

378-383.

[4] Klotz, T., Straube, B.,Fordham, E., Haufe,

J., Schulze, F., Turek, K., Schmidt, T, An

Approach to the verification of Material

Handling Systems, Emerging Tech-nologies

& Factory Automation (ETFA) 2011,

IEEE16th Conference

10.1109/ETFA..2011.6059043, 1-8.

[5] Masao Ogawa and Yutaka Henmi, Recent

development on PC and PLC based Control

Systems for Beer Brewery Process

Automation Applications, SICE-ICA SE

International Joint Conference 2006, Oct

18- 21, 2006 in Bexco, Bussan, Koria, 1053-

1056.

[6] Schulze, S., Webber, S., Improving

Customer Satisfaction Through Establishing

Strategic Goals for Quality and productivity

Improvement, Global Telecommunications

Conference, Vol.1, 1991, 148-152.

[7] Sivkumar, A., Saravanan, K., Karthikeyan,

C., Suriaprakash Rao, K., Navaneeth

krishnan P, A Simulation Solution for

Improvement of Quality and productivity in

Failure Textile Industry, International

Conference Communication and

S

r.

Problems

faced

Cost before solving

the problem (Rs.)

Benefit after

solving the

problem (Rs.)

1. Leakage of

bend pipe 13,38,800/- 13,38,800/-

2. Choking of

bags 10,48,133/- 10,48,133/-

3. Vibration of

hammer mill 40,850/- 40,850/-

Total 24,27,753/- 24,27,753/-

http://dx.doi.org/10.1109/ETFA.2011.6059043




2537 | P a g e

Computational Intelligence (INC OCCI)

on IEEE Conference publications 2010,

17-21.

[8] M.S. Mahajan, Statistical quality control

(Dhanpat Rai and Co (P) Ltd.,Third

Revised Edition, New Delhi), 426-428,

469-472.

[9] Hamadallah Mohammad Al-Baijat, The

Use of Basalt Aggregates in Concrete

Mixes in Jordan, Jordan Jounal of Civil

Engineering, Volume 2, No.1, 2008, 63-

70.

[10] N.S.V. Kameswara Rao, Mechanical

vibrations of elastic systems (Asian Books

Private Limited, First Edition, New

Delhi), 29-32.

[11] Bon, A. T., Lim ping ping,

Implementation of Total Productive

Maintenance (TPM) in Automotive

Industry, Business, Engineering and

Industrial Applications (ISBEIA) 2011,

IEEE symposium on 10.

1109/ISBE.2011.6088881,55-58.

[12] P. Radhakrishanan, S. Subramanian, V.

Raju, CAD/CAM/CIM (New age

international Publisher, Second Edition,

New Delhi, 81-224-1248-3), 329-339

Fig. 12. Automated material handling system of liquor manufacturing plant (Using Pneumatic Conveying

System)

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